Flexible Magnetic Interconnects for Reconfigurable Modules
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Solution Overview
Problem
Conventional electrical connectors face limitations such as high cost, awkward assembly, bulky size, fragility, and restricted shape and size compatibility, along with difficulties in disassembly and damage susceptibility, particularly in forming durable and easily reconfigurable connections between electronic and lighting modules.
Innovation Solution
The use of flexible magnetic interconnects, which employ a magnetic structure within a recessed module and a compliant contact that changes shape under magnetic attraction to establish and maintain electrical and mechanical connections between modules, allowing for easy assembly, disassembly, and reconfiguration without external mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pin and socket connectors are used, then electrical connections can be established, but the system becomes bulky, fragile, and difficult to assemble/disassemble
Solution Approach 1:
The patent replaces conventional mechanical pin-and-socket connectors with a magnetic field-based connection system. Magnets embedded in the connector housings generate magnetic attraction forces that hold male and female connectors together, eliminating the need for complex mechanical interlocking structures. This substitution reduces structural complexity while improving connection reliability and ease of assembly/disassembly.
Solution Approach 2:
The patent changes the fundamental connection mechanism from mechanical interlocking to magnetic field interaction. By using magnetic field strength as the binding parameter instead of mechanical geometry, the system achieves simpler structures with improved reliability. The magnetic force can be tuned by adjusting magnet strength and positioning, providing flexible control over connection characteristics.
2Ease of operation
If conventional connectors with spring contacts are used, then electrical connections are maintained, but insertion force is required and alignment tolerances are restricted
Solution Approach 1:
The patent replaces mechanical spring contacts with conductive elastomeric materials that conform to mating surfaces under magnetic attraction. This eliminates the need for precise alignment tolerances and insertion force, as the elastomeric material automatically adapts to the mating connector geometry through elastic deformation, achieving ease of operation without stringent manufacturing precision requirements.
Solution Approach 2:
The patent uses conductive elastomeric strips or films as the contact mechanism instead of rigid spring contacts. These flexible conductive elements can deform to accommodate misalignment and vary in shape to match the mating surface, providing robust electrical connection with relaxed alignment tolerance requirements while maintaining ease of assembly.
3Adaptability or versatility
If breakaway magnetic connectors with discrete contacts are used, then magnetic retention is achieved, but contact insertion force must be overcome and secondary clamping is required
Solution Approach 1:
The patent merges the magnetic retention function with the electrical contact function into a unified system. The magnets are positioned to simultaneously provide both the holding force and the contact force, eliminating the need for separate spring contacts and clamping mechanisms. This integration reduces device complexity while maintaining connection flexibility and adaptability.
Solution Approach 2:
The magnetic field automatically provides both retention and contact force without requiring external clamping mechanisms or secondary processes. When the connectors are brought together, the magnetic attraction self-generates the necessary forces for both electrical contact and mechanical retention, making the system self-sufficient and reducing overall complexity.
4Ease of manufacture
If conventional connectors are used, then electrical connections are established, but the connectors are costly and have bulky appearance
Solution Approach 1:
The patent replaces bulky mechanical connector structures with compact magnetic assemblies. The magnets can be small embedded elements within the housing, and the conductive elastomeric contacts require minimal space compared to traditional spring contacts and shielding structures. This reduction in volume lowers material costs and manufacturing complexity, improving ease of manufacture while reducing connector size.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a robust, cost-effective, and flexible connection system that is durable, adaptable to various module shapes and sizes, and maintains electrical continuity even when modules are moved relative to each other, eliminating the need for tight mechanical tolerances and external pressure.
Implementation Method 1
movement of the magnetic structure is caused by magnetic attraction between the magnetic structure and an external magnetic structure
Implementation Method 2
the flexible circuit includes a compliant contact, which changes shape by movement of the magnetic structure
Data Source
AI summary
A flexible magnetic interconnect is disclosed. In one embodiment, an apparatus includes a module having a recess therein. A magnetic structure is moveable within the recess and a flexible circuit cooperates with the module to retain the magnetic structure within the recess. Movement of the magnetic structure is caused by magnetic attraction between the magnetic structure and an external magnetic structure. The flexible circuit includes a compliant contact, which changes shape by movement of the magnetic structure.